user manual - onrobot€¦ · 3 onrobot package programming ... this document is intended for...

USER MANUAL HEX

Force Torque Sensor

For the KUKA KRC4

Edition E9

OnRobot FT KUKA Software Version 4.0.0

September 2018

OnRobot © 2018 www.onrobot.com

Content

1 Preface ................................................................................................................................ 5

1.1 Target Audience ..................................................................................................................... 5

1.2 Intended Use .......................................................................................................................... 5

1.3 Important safety notice ......................................................................................................... 5

1.4 Warning Symbols ................................................................................................................... 5

1.5 Typographic Conventions ...................................................................................................... 6

2 Getting Started .................................................................................................................... 7

2.1 Scope of Delivery .................................................................................................................... 7

2.2 Mounting ................................................................................................................................ 8

2.2.1 ISO 9409-1-50-4-M6 Tool Flange ............................................................................... 8

2.2.2 ISO 9409-1-31.5-7-M5 Tool Flange ............................................................................ 8

2.2.3 ISO 9409-1-40-4-M6 Tool Flange ............................................................................... 9

2.3 Cable Connections ................................................................................................................ 10

2.4 Software Installation ........................................................................................................... 10

2.4.1 KUKA Line Interface Setup (Ethernet) ......................................................................... 10

2.4.2 KUKA Robot Sensor Interface Package Installation ................................................... 13

2.4.3 OnRobot KUKA Software Installation ......................................................................... 16

3 OnRobot Package Programming ........................................................................................ 19

3.1 Overview ............................................................................................................................... 19

3.1.1 KRL variables ................................................................................................................ 19

3.1.2 KRL functions and subprograms ................................................................................. 19

3.2 Initialization .......................................................................................................................... 19

3.2.1 OR_INIT() ...................................................................................................................... 19

3.3 Hand Guide ........................................................................................................................... 19

3.3.1 OR_HANDGUIDE() ........................................................................................................ 19

3.4 Path recording and replay .................................................................................................... 20

3.4.1 Recording a path .......................................................................................................... 20

3.4.2 Replaying a path: OR_PATH_REPLAY() ...................................................................... 23

3.5 Force control ........................................................................................................................ 24


3.5.1 OR_BIAS() ..................................................................................................................... 24

3.5.2 OR_FORCE_TORQUE_ON() ........................................................................................ 24

3.5.3 OR_FORCE_TORQUE_OFF() ....................................................................................... 25

3.5.4 OR_WAIT() .................................................................................................................... 25

3.5.5 Example force control .................................................................................................. 25

4 Glossary of Terms .............................................................................................................. 27

5 List of Acronyms ................................................................................................................ 28

6 Appendix ........................................................................................................................... 29

6.1 Changing the IP of the Compute Box .................................................................................. 29

6.2 Software Uninstallation ....................................................................................................... 30

6.3 Editions ................................................................................................................................. 31

Preface 4


Copyright © 2017-2018 OnRobot A/S. All rights Reserved. No part of this publication may be

reproduced, in any form or by any means, without the prior written permission of OnRobot

A/S.

Information provided within this document is accurate to the best of our knowledge at the

time of its publication. There may be differences between this document and the product if

the product has been modified after the edition date.

OnRobot A/S. does not assume any responsibility for any errors or omissions in this document.

In no event shall OnRobot A/S. be liable for losses or damages to persons or property arising

from the use of this document.

The information within this document is subject to change without notice. You can find the

latest version on our webpage at: https://onrobot.com/.

The original language for this publication is English. Any other languages that are supplied

have been translated from English.

All trademarks belong to their respective owners. The indications of (R) and TM are omitted.

https://optoforce.com/

Preface 5


1 Preface

1.1 Target Audience

This document is intended for integrators who design and install complete robot

applications. Personnel working with the sensor are expected to have the following

expertise:

Basic knowledge of mechanical systems

Basic knowledge of electronic and electrical systems

Basic knowledge of the robot system

1.2 Intended Use

The sensor is designed for measuring forces and torques, installed on the end effector of a

robot. The sensor can be used within the specified measurement range. Using the sensor

outside of its range is considered misuse. OnRobot is not liable for any damage or injury

resulting from misuse.

1.3 Important safety notice

The sensor is partly completed machinery and a risk assessment is required for each

application the sensor is a part of. It is important that all safety instructions herein are

followed. The safety instructions are limited to the sensor only and do not cover the safety

precautions of a complete application.

The complete application must be designed and installed, in accordance with the safety

requirements specified in the standards and regulations of the country where the application

is installed.

1.4 Warning Symbols

DANGER:

This indicates a very dangerous situation which, if not avoided, could result in injury or death.

WARNING:

This indicates a potentially hazardous electrical situation which, if not avoided, could result in injury or damage to the equipment.

WARNING:

This indicates a potentially hazardous situation which, if not avoided, could result in injury or major damage to the equipment.

CAUTION:

This indicates a situation which, if not avoided, could result in damage to the equipment.

Preface 6


NOTE:

This indicates additional information such as tips or recommendations.

1.5 Typographic Conventions

The following typographic conventions are used in this document.

Table 1: Conventions

Courier Text File paths and file names, code, user input and computer output.

Italicized text Citations and marking image callouts in text.

Bold text UI elements, including text appearing on buttons and menu options.

Bold, blue text External links, or internal cross-references.

<angle brackets> Variable names that must be substituted by real values or strings.

1. Numbered lists Steps of a procedure.

A. Alphabetical lists Image callout descriptions.

Getting Started 7


2 Getting Started

2.1 Scope of Delivery

In the KUKA KRC4 OnRobot HEX Sensor Kit everything is provided that is required to connect

the OnRobot force/torque sensor to your KUKA robot.

• OnRobot 6-axis force/torque sensor (variant HEX-E or HEX-H)

• OnRobot Compute Box

• OnRobot USB Drive

• Adapter-A2, B2, or C2

• sensor cable (4 pin M8 - 4 pin M8, 5 m)

• Compute Box power cable (3 pin M8 – open ended)

• Compute Box power supply

• UTP cable (RJ45 - RJ45)

• PG16 cable gland

• plastic bag, containing:

o cable holder, with integrated screw

o M6x8 screws (10)

o M5x8 screws (9)

o M4x6 screws (7)

o M6 washer (10)

o M5 washer (9)

Getting Started 8


2.2 Mounting

Use only the screws provided with the sensor. Longer screws could damage the sensor or

the robot.

2.2.1 ISO 9409-1-50-4-M6 Tool Flange

To mount the sensor to ISO 9409-1-50-4-M6 tool flange, follow this process:

1. Fasten Adapter-A2 to the robot by four M6x8 screws. Use 6 Nm tightening torque.

2. Fasten the Sensor to the adapter by five M4x6 screws. Use 1,5 Nm tightening

torque.

3. Fasten the cable to the Sensor with the Cable Holder by the M4x12 screw. Use 1,5

Nm tightening torque.

Legend: 1 – robot tool flange, 2 – Adapter-A2, 3 - M6x8 screws, 4 – M6 washers, 5 – M4x6 screws, 6– sensor, 7 –

cable holder

2.2.2 ISO 9409-1-31.5-7-M5 Tool Flange

To mount the sensor to ISO 9409-1-31.5-7-M5 tool flange, follow this process:

Fasten Adapter-B2 to the Robot by seven M5x8 Screws. Use 4 Nm tightening torque.

Fasten the Sensor to the adapter by five M4x6 screws. Use 1,5 Nm tightening torque.

Fasten the cable to the Sensor with the Cable Holder by the M4x12. Use 1,5 Nm

tightening torque.

Getting Started 9


Legend: 1 – robot tool flange, 2 – Adapter-B2, 3 – M5x8 screws, 4 – M5 washers, 5 – M4x6 screws, 6 – sensor, 7 –

cable holder

2.2.3 ISO 9409-1-40-4-M6 Tool Flange

To mount the sensor to ISO 9409-1-40-4-M6 tool flange, follow this process:

1. Fasten Adapter-C2 to the Robot by four M6x8 Screws. Use 6 Nm tightening torque.

Fasten the Sensor to the adapter by five M4x6 screws. Use 1,5 Nm tightening torque.

Fasten the cable to the Sensor with the Cable Holder by the M4x12 screw. Use 1,5

Nm tightening torque.

Legend: 1 – robot tool flange, 2 – Adapter-C2, 3 - M6x8 screws, 4 – M6 washers, 5 – M4x6 screws, 6– sensor, 7 –

cable holder

Getting Started 10


2.3 Cable Connections

To connect the sensor, follow this process:

1. Connect the 4 pin M8 cable (5m long) to the sensor and secure it to the robot with

cable ties.

Make sure that enough extra cable length is available around the joints for bending.

2. Place the converter somewhere near the KUKA robot control cabinet and connect

the 4 pin M8 sensor cable.

3. Connect the Compute Box’s Ethernet interface with the KUKA controller’s Ethernet

interface (KLI) via the supplied UTP cable (yellow).

4. Use the Compute Box power supply to power the Compute Box, and the sensor from

a wall socket.

5. Apply the correct network settings to both the Ethernet converter and the KUKA

robot. The default Ethernet converter IP address is 192.168.1.1. If you need to

change the IP address of the sensor, see Changing the IP of the Sensor.

2.4 Software Installation

2.4.1 KUKA Line Interface Setup (Ethernet)

To change the IP settings of the KUKA robot controller, follow this process:

Getting Started 11


1. Go to ‘Configuration’ > ‘User group’

2. Select ‘Expert’ and type in your password

3. Go to ‘Start-up’ > ‘Network configuration’

4. Set the IP address to be on the same subnet as the Compute Box

Getting Started 12


5. Click save 6. Accept the prompts and restart the robot controller

Getting Started 13


2.4.2 KUKA Robot Sensor Interface Package Installation

1. Go to ‘Start-up’ > ‘Additional software', click on ‘New software’

2. If no packages are listed click on ‘Configure’.

3. Click on an empty slot and click ‘Path selection’

4. Browse for the installation folder of RSI, then click ‘Save’ twice

Getting Started 14


5. Mark the check box next to the RSI package name

6. Wait for the installation, accept all prompts

7. Click ‘Yes’ when asked to reboot the robot controller

8. After the reboot go to ‘Start-up’ > ‘Service’ > ‘Minimize HMI’

Getting Started 15


9. Click on the Start menu and open the ‘RSI-Network’ application

10. Click on the ‘New’ field under ‘RSI-Ethernet’ and click ‘Edit’. Enter an IP address with a different subnet that KLI

Getting Started 16


2.4.3 OnRobot KUKA Software Installation

Go to ‘Main Menu’>‘Configuration’>’User group’ and select ‘Expert’ mode. Enter

your password, then go to ‘Start-up’>’Service’>’Minimize HMI’.

Plug the provided USB-drive into one of the control box’s USB ports.

Browse for the OnRobot KUKA Setup program and launch it. This program has

multiple purposes: You can use it for the initial installation of the OnRobot KUKA

package, but also as a network configuration tool.

On the welcome screen click next.

On the next window you will find three input fields. The first is for defining the

Compute Box to be used with your robot. The second and third one is for defining

the RSI connection.

First enter the IP address of the compute box you want to use with the robot. The

default address is 192.168.1.1, use this if your Compute Box has not been configured

yet or if it is set to fixed IP mode.

After entering the IP address click on ‘Check’. If the program successfully makes a

connection to the Compute Box a green tick mark will appear along with the name of

the sensor plugged into the box, and the version of the Compute Box software.

After successfully setting the Compute Box IP, continue by entering the IP and

subnet mask for the RSI connection.

The IP you enter here must be on the same subnet as the one you defined during the

RSI setup. (E.g.: if you set 192.168.173.1 for RSI on the robot controller set

192.168.173.X here. X can be any number between 2 and 255.) Make sure that you

also use the same subnet mask as on the robot controller.

Getting Started 17


After filling in all the fields click on ‘Install’ to complete the

installation/configuration. If the installation has been successful a green tick mark

will appear. Installation failure can happen if there’s a problem with the connection

to the Compute Box or there’s write protection on the robot controller’s hard drive.

To complete the setup, go back to the Smart HMI and in the Navigator go to

‘D:\OnRobot’. Select ‘OnRobotFT.src’ and ‘OnRobotFT.dat’, then in the

‘Edit’ menu press copy.

Getting Started 18


Go to ‘KRC:\R1\TP’ and create a folder with the following name: OnRobot. Paste

the two files into the new folder.

Restart the robot controller.

OnRobot Package Programming 19


3 OnRobot Package Programming

3.1 Overview

3.1.1 KRL variables

STRUC OR_AXEN BOOL X,Y,Z,A,B,C

Structure used for enabling or disabling axes for force control.

STRUC OR_FORCE_TORQUE_PARAM

Structure used for defining the force control parameters. This structure has numerous fields

that will be discussed in the force-torque control section.

3.1.2 KRL functions and subprograms

OR_INIT()

OR_BIAS()

OR_HANDGUIDE()

OR_PATH_REPLAY()

OR_WAIT()

OR_FORCE_TORQUE_ON()

OR_FORCE_TORQUE_OFF()

3.2 Initialization

3.2.1 OR_INIT()

This subprogram must be inserted into any code using OnRobot force control commands to

initialize parameters for the proper behavior of all commands. It must be included only once

and must be before the first OnRobot command.

3.3 Hand Guide

3.3.1 OR_HANDGUIDE()

This subprogram launches the sensor guided hand-guide on the robot. The program includes

a BCO move to the actual position the program is launched at. Do not touch the sensor or

any attached tools upon starting the program.

The argument of this subprogram is used for limiting the motion of the robot along or about

certain axes. In the example below movement along the Z-axis is disabled along with

rotations around the A- and B-axes.



OR_HANDGUIDE has a conservative speed limit on it, but

Example:

DECL OFAXEN ENABLED_AXES

ENABLED_AXES={X TRUE, Y TRUE, Z FALSE, A FALSE, B FALSE, C

TRUE}

OR_INIT()

OR_HANDGUIDE(ENABLED_AXES)

3.4 Path recording and replay

3.4.1 Recording a path

You can record any movement the robot does, be it a path created by manually hand guiding

the robot or the shape of a surface during a force-controlled movement. In any case, the

path recording must be initiated manually using the path recording GUI. The GUI can be

summoned using the ‘On’ icon on the left side toolbar of the SmartHMI.

In order to record a hand guided path, the following steps should be followed:

1. Create a program (or use the provided example program) that has a

OR_HANDGUIDE() command in it to launch hand guiding.

2. Select the program and start it. It is recommended that you use a Teach mode for

this.

3. Move the robot into the position that you want to start the path recording from. You

can use hand guiding for this, but since all recorded paths are considered as relative

motions it is recommended to use explicit programmed positions as starting points.

This makes replaying and path reusability easier.

4. When the robot is in hand guiding mode and in the correct initial position, select the

icon on the left toolbar to bring up the path recording GUI.

5. Press Start Path Recording to begin your recording session.



6. Move the robot along the path you wish to record.

7. When you’re done with the recording press Stop Path Recording.



8. If you’re satisfied with the recorded path click on Save Path.

The new path will be added to the list on the left and its identifier will be displayed

next to Last saved path. The path is now saved on the Compute Box.



This process can be used to record force-controlled movements too. This can greatly

improve the accuracy and speed of the force control.

Saved paths can be exported via the Compute Box webpage and uploaded to a different

Compute Box. Saved paths are interchangeable between robot makes (e.g. a path recorded

on a KUKA robot can be replayed on any other robot supported by the Compute Box)

3.4.2 Replaying a path: OR_PATH_REPLAY()

This function can be used to replay paths stored on the Compute Box. The commands have

three arguments:

OR_PATH_REPLAY(SPEED:IN,ACCELERATION:IN,PATHID:IN)

SPEED: The constant translational speed, in mm/s, used for replaying the path. This speed is

global; thus, the robot will attempt to replay all movements at this speed. For this reason,

rotations without translation should be avoided.

ACCELERATION: The acceleration and the deceleration, in mm/s2, used for replaying the

path. Use a lower number to achieve a softer acceleration at the beginning and the end of

the path.

PATHID: The 4-number identifier of the path to be replayed.

Return values:

9: Path completed

-1: General error

-11: Specified path not found

-13: Specified path is empty

-14: Unable to open specified path file.

Example:

DECL INT retval

OR_INIT()

PTP {A1 0,A2 -90, A3 90, A4 0, A5 90, A6 0}

retval = OR_PATH_REPLAY(50, 50, 9159)



3.5 Force control

3.5.1 OR_BIAS()

Used for resetting the sensor values for a given load. Used for initial biasing of the sensor

values during force control (except hand guiding) or biasing when the orientation of the

sensor changes.

3.5.2 OR_FORCE_TORQUE_ON()

Activates the force control with predefined parameters. After the activation of the force

control all movements will be superposed on the force control (either KUKA movement

commands or path replay).

OR_FORCE_TORQUE_ON(PARAM:IN)

PARAM is the structure OR_FORCE_TORQUE_PARAM with the following fields:

FRAME_TYPE: The movement frame used for the force control. #BASE is the base

coordinate system of the robot, fixed to the robot base. #TOOL is the frame fixed to the

robot flange.

ENABLE: Defines the compliant axes with the OR_AXEN structure.

FRAME_MOD: Frame offset of the used coordinate system. Primary use is the rotation of

the coordinate axes for force control along an oblique axis or plane.

P_GAIN: Proportional gain for the force controller. This is the most used parameter for

basic force control. Determines how quickly the robot reacts to changes in force but can

cause oscillations. These values should start small (1 for force, 0.1 for torque) and

gradually increased to improve behavior.

I_GAIN: Integral gain of the force controller. Can be used to correct for persistent force

errors (e.g. a sloped surface). Slows robot reactivity, increases overshooting.

D_GAIN: Derivative gain of the force controller. Can be used for damping controller

induced oscillations. Slows robot reactivity, high value increases oscillations.

FT: Definition of the target force to be held along the axes defined by FRAME_TYPE and

FRAME_MOD. Disabled axes will ignore this parameter.

F_SQR_TH: Force threshold for squared force sensitivity. Can be used as a soft force

cutoff in low force cases (the lower the force, the less sensitive, reduces oscillations). If

used all GAIN values must be drastically reduced.

T_SQR_TH: Torque threshold for squared torque sensitivity. Can be used as a soft torque

cutoff in low torque cases (the lower the torque, the less sensitive, reduces oscillations).

If used all GAIN values must be drastically reduced.



MAX_TRANS_SPEED: Maximum translational speed allowed by the force controller.

[mm/s]

MAX_ROT_SPEED: Maximum angular velocity allowed by the force controller. [deg/s]

3.5.3 OR_FORCE_TORQUE_OFF()

This subprogram switches off the force control.

3.5.4 OR_WAIT()

Wait specified amount of time during force control.

OR_WAIT(TIMEOUT:IN)

TIMEOUT: Amount of time elapsed during the wait in milliseconds.

Return value: 7: The specified amount of time passed.

3.5.5 Example force control

This example shows the parametrization of a force control movement that is compliant

along all three translational axes while holding 20N in tool-z direction. After activation the

robot waits two seconds (e.g. robot moves into contact) then moves 200 mm in the X-

direction.

DECL OR_AXEN enable

DECL OR_FORCE_TORQUE_PARAM param

DECL POS pgain, dgain, igain, framemod, force

DECL INT retval, tmp

OR_INIT()

PTP {A1 0,A2 -90, A3 90, A4 0, A5 90, A6 0}

OR_BIAS()

enable = {X TRUE, Y TRUE, Z TRUE, A FALSE, B FALSE, C

FALSE}

pgain = {X 1, Y 1, Z 1, A 0.1, B 0.1, C 0.1}

dgain = {X 0, Y 0, Z 0, A 0, B 0, C 0}

igain = {X 0, Y 0, Z 0, A 0, B 0, C 0}

framemod = {X 0, Y 0, Z 0, A 0, B 0, C 0}

force = {X 0, Y 0, Z 20, A 0, B 0, C 0}

param.FRAME_TYPE = #TOOL

param.ENABLE = enable

param.FRAME_MOD = framemod



param.P_GAIN = pgain

param.I_GAIN = igain

param.D_GAIN = dgain

param.FT = force

param.F_SQR_TH = 0

param.T_SQR_TH = 0

param.MAX_TRANS_SPEED = 0

param.MAX_ROT_SPEED = 0

OR_FORCE_TORQUE_ON(param)

;WAIT 2 sec

tmp = OR_WAIT(2000)

;KUKA MOVE

PTP_REL {X 200}

OR_FORCE_TORQUE_OFF()

Glossary of Terms 27


4 Glossary of Terms

Term Description

Compute Box A unit provided by OnRobot along with the sensor. It performs the calculations needed to use the commands and applications implemented by OnRobot. It needs to be connected to the sensor and the robot controller.

OnRobot Data Visualization

Data visualization software created by OnRobot, to visualize the data provided by the sensor. Can be installed on Windows operating system.

List of Acronyms 28


5 List of Acronyms

Acronym Expansion

DHCP Dynamic Host Configuration Protocol

DIP dual in-line package

F/T Force/Torque

ID Identifier

IP Internet Protocol

IT Information technology

MAC media access control

PC Personal Computer

RPY Roll-Pitch-Yaw

SP Starting Position

SW software

TCP Tool Center Point

UTP unshielded twisted pair

Appendix 29


6 Appendix

6.1 Changing the IP of the Compute Box

To change the IP address of the sensor, connect your laptop or an external PC to the

OnRobot Compute Box.

1. Make sure that the device is not powered. Connect the device and the computer with the provided Ethernet cable.

2. If your device is in the factory default settings, proceed to step 3. Otherwise, make

sure to switch the DIP switch 3 to the ON position (up) and the DIP switch 4 to the OFF position (down).

3. Power the device from the provided power supply and wait 30 seconds for the device to boot up.

4. Open a web browser (Internet Explorer is recommended) and navigate to

http://192.168.1.1. The welcome screen is displayed.

5. Click on Configuration in the top-side menu. The following screen is displayed:

6. Select the Static IP option from the Network mode drop down menu.

7. Edit the IP Address.

8. Set DIP switch 3 to off position.

http://192.168.1.1/

Appendix 30


9. Click the Save button

10. Open a web browser (Internet Explorer is recommended) and navigate to the IP Address set in step 7.

6.2 Software Uninstallation

The following steps will uninstall the OnRobot package from your robot controller:

1. Enter ‘Expert’ mode by going to the Main Menu then ‘Configuration’>’User group’.

2. Minimize the user interface with ‘Start-up’>’Service’>’Minimize HMI’.

3. Open the file explorer and go to ‘D:\OnRobot’.

4. Launch the OnRobot Setup executable file.

5. Click on ‘Uninstall’ and accept the prompts.

6. Restart the robot controller.

Appendix 31


6.3 Editions

Edition Comment

Edition 2 Document restructured.

Glossary of Terms added.

List of Acronyms added.

Appendix added.

Target audience added.

Intended use added.

Copyright, Trademark, contact information, original language information added.

Edition 3 Editorial changes.




user manual - onrobot€¦ · 3 onrobot package programming ... this document is intended for...

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